Processes for producing filter cartridge assemblies and molded polyurethane elastomers

ABSTRACT

Disclosed are processes for producing molded polyurethane elastomers and products, such as filter end caps, that include such elastomers. The elastomers are the reaction product of a non-foaming reaction mixture comprising an isocyanate-reactive composition and an organic polyisocyanate prepolymer with an internal mold release agent.

FIELD

The present invention relates to processes for producing filtercartridge assemblies that include a molded polyurethane elastomerend-cap, as well as to methods for making molded polyurethaneelastomers.

BACKGROUND

Filter cartridge assemblies, such as those used to filter water inswimming pool and spa applications, are often constructed of a body,which is often cylindrical (although other shapes are also possible).The body comprises a filter medium. To produce the filter cartridgeassembly, end-caps are affixed at opposite ends of the body. Theseend-caps are sometimes affixed to the filter medium by immersing thefilter medium into a polyurethane reaction mixture that will hardenabout the end of the filter medium to form an elastomeric end-cap. Thepolyurethane reaction mixture is placed in a mold so that, when ithardens, the end-cap has the desired shape. To be suitable as a filterend-cap, especially for filters used in swimming pool and spaapplications, the resulting polyurethane elastomer should have excellentimpact resistance, tear strength, suitable hardness, sometimesexhibiting a Shore D hardness of at least about 80, and be resistant tochemicals to which the filter cartridge assembly will be exposed.

One of the drawbacks of the foregoing molding process to produce suchfilter cartridge assemblies is that external mold release agents areused to produce the assembly. This mold release agent, typically asilicone material, is applied to the mold so that the filter cartridgeassembly can be removed from the mold relatively easily and with littleor no damage to the end-cap. The external mold release agent, however,is, depending on the shape of the mold, either wiped on the mold orsprayed onto the mold to access harder to reach areas. These processesare labor intensive and, in the case of spray application of the moldrelease agent, undesirable due to the presence of solvents in thesilicone spray. Internal mold release agents in a polyurethane reactionmixture can, however, reduce the reactivity of the reaction mixture andincrease the time it takes for the polyurethane elastomer to achieve agreen strength sufficient for the end-cap to be demolded without damage,thereby reducing productivity.

As a result, it would be desirable to provide processes for producingmolded polyurethane elastomers that can be an end-cap of a filtercartridge assembly utilizing isocyanates with an internal mold releaseagent, thereby eliminating the need to apply an external mold releaseagent to the mold prior to production of each, or nearly each, filterend-cap. It would be desirable that such processes still provide afilter end-cap exhibiting required physical properties, such as hardnesssufficient for use with filters used in swimming pool and spaapplications, all without negatively impacting manufacturingproductivity.

SUMMARY

In certain respects, the present specification is directed to processesof making a filter cartridge assembly comprising an end member and abody comprising a filter medium. These processes comprise affixing theend member to an end of the body, wherein the end member is apolyurethane elastomer that is a reaction product of a non-foamingreaction mixture comprising an isocyanate-reactive composition and anorganic polyisocyanate prepolymer having an internal mold release agent,wherein the isocyanate-reactive composition comprises 1% to 10% byweight, based on the total weight of isocyanate-reactive ingredients inthe isocyanate-reactive composition, of a polyether tetrol that is analkylene diamine-alkylene oxide adduct having a number average molecularweight of 150 to 500 gram/mole.

In other respects, the present specification is directed to processesfor producing a molded polyurethane elastomer. These processes comprisedepositing a non-foaming reaction mixture into a mold, the non-foamingreaction mixture comprising: (a) an organic polyisocyanate prepolymerhaving an internal mold release agent; and (b) an isocyanate-reactivecomposition comprising: (i) 1% to 10% by weight, based on the totalweight of isocyanate-reactive ingredients in the isocyanate-reactivecomposition, of a polyether tetrol that is an alkylene diamine-alkyleneoxide adduct having a number average molecular weight of 150 to 500gram/mole; (ii) a polyether polyol prepared from an initiator which isnot an amine that has a hydroxyl functionality greater than 2 and anumber average molecular weight of 150 to 500 gram/mole; and (iii) 40 to80 percent by weight, based on the total weight of theisocyanate-reactive composition, of a polyether polyol having afunctionality of 3 and a number average molecular weight of 600 to 800gram/mole. In these processes, the polyether tetrol (i) and thepolyether polyol prepared from an initiator which is not an amine (ii)are present in the isocyanate-reactive composition in a relative weightratio of 2:1 to 4:1.

In yet other respects, the present specification is directed toprocesses of making a filter cartridge assembly comprising an end memberand a body comprising a filter medium, comprising affixing the endmember to an end of the body. In these processes, the end member is apolyurethane elastomer that is a reaction product of a non-foamingreaction mixture comprising an isocyanate-reactive composition and anorganic polyisocyanate prepolymer having an internal mold release agent,wherein the isocyanate-reactive composition comprises a mixture ofpolyols formulated to provide a polyurethane elastomer having a Shore Dhardness, measured according to ASTM D2240-15, within 10 minutes afterproduction that is at least 60% of the Shore D hardness of thepolyurethane elastomer measured 16 hours after production.

The present specification is also directed to, among other things,molded polyurethane elastomers produced from processes of the presentspecification and products, including, but not limited to, filterend-caps and filter cartridge assemblies, produced by processesdescribed in this specification.

DETAILED DESCRIPTION

Various embodiments are described and illustrated in this specificationto provide an overall understanding of the structure, function,properties, and use of the disclosed inventions. It is understood thatthe various embodiments described and illustrated in this specificationare non-limiting and non-exhaustive. Thus, the invention is not limitedby the description of the various non-limiting and non-exhaustiveembodiments disclosed in this specification. The features andcharacteristics described in connection with various embodiments may becombined with the features and characteristics of other embodiments.Such modifications and variations are intended to be included within thescope of this specification. As such, the claims may be amended torecite any features or characteristics expressly or inherently describedin, or otherwise expressly or inherently supported by, thisspecification. Further, Applicant(s) reserve the right to amend theclaims to affirmatively disclaim features or characteristics that may bepresent in the prior art. Therefore, any such amendments comply with therequirements of 35 U.S.C. § 112 and 35 U.S.C. § 132(a). The variousembodiments disclosed and described in this specification can comprise,consist of, or consist essentially of the features and characteristicsas variously described herein.

Any patent, publication, or other disclosure material identified hereinis incorporated by reference into this specification in its entiretyunless otherwise indicated, but only to the extent that the incorporatedmaterial does not conflict with existing definitions, statements, orother disclosure material expressly set forth in this specification. Assuch, and to the extent necessary, the express disclosure as set forthin this specification supersedes any conflicting material incorporatedby reference herein. Any material, or portion thereof, that is said tobe incorporated by reference into this specification, but whichconflicts with existing definitions, statements, or other disclosurematerial set forth herein, is only incorporated to the extent that noconflict arises between that incorporated material and the existingdisclosure material. Applicant(s) reserves the right to amend thisspecification to expressly recite any subject matter, or portionthereof, incorporated by reference herein.

In this specification, other than where otherwise indicated, allnumerical parameters are to be understood as being prefaced and modifiedin all instances by the term “about”, in which the numerical parameterspossess the inherent variability characteristic of the underlyingmeasurement techniques used to determine the numerical value of theparameter. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter described in the present description should atleast be construed in light of the number of reported significant digitsand by applying ordinary rounding techniques.

Also, any numerical range recited in this specification is intended toinclude all sub-ranges of the same numerical precision subsumed withinthe recited range. For example, a range of “1.0 to 10.0” is intended toinclude all sub-ranges between (and including) the recited minimum valueof 1.0 and the recited maximum value of 10.0, that is, having a minimumvalue equal to or greater than 1.0 and a maximum value equal to or lessthan 10.0, such as, for example, 2.4 to 7.6. Any maximum numericallimitation recited in this specification is intended to include alllower numerical limitations subsumed therein and any minimum numericallimitation recited in this specification is intended to include allhigher numerical limitations subsumed therein. Accordingly, Applicant(s)reserves the right to amend this specification, including the claims, toexpressly recite any sub-range subsumed within the ranges expresslyrecited herein. All such ranges are intended to be inherently describedin this specification such that amending to expressly recite any suchsub-ranges would comply with the requirements of 35 U.S.C. § 112 and 35U.S.C. § 132(a).

The grammatical articles “one”, “a”, “an”, and “the”, as used in thisspecification, are intended to include “at least one” or “one or more”,unless otherwise indicated. Thus, the articles are used in thisspecification to refer to one or more than one (i.e., to “at least one”)of the grammatical objects of the article. By way of example, “acomponent” means one or more components, and thus, possibly, more thanone component is contemplated and may be employed or used in animplementation of the described embodiments. Further, the use of asingular noun includes the plural, and the use of a plural noun includesthe singular, unless the context of the usage requires otherwise.

As indicated, certain embodiments of the present specification aredirected to processes for producing a molded polyurethane elastomer. Theelastomer is, in some embodiments, embodied as an end-cap affixed to anend of a body of a filter cartridge assembly, the body comprising afilter medium. The filter cartridge assembly is, in certain embodiments,used for filtering a liquid, such as water, and, in some embodiments, isemployed in an aquatic application, such as swimming pools and spas, andthe like. In certain embodiments, the filter medium is a pleatedmaterial, such as, for example, a spun bonded polyester, polypropyleneor cotton though other filter medium can be employed if desired. Thefilter cartridge assembly, and the body, in certain embodiments, has agenerally cylindrical structure and the end-caps, in certainembodiments, are generally circular. One example of a filter cartridgeassembly encompassed by the present specification is described in U.S.Pat. No. 5,211,846 at col. 4, line 4 to col. 11, line 42, the citedportion of which being incorporated herein by reference.

The processes of the present specification comprise depositing anon-foaming reaction mixture into a mold. One suitable technique ofdepositing the reaction mixture into the mold is a one-shot technique inwhich an isocyanate functional component and an isocyanate-reactivecomposition are separately supplied to a mixhead, where they are mixed,and the mixture is then injecting into a mold. One-shot processes aredisclosed in U.S. Pat. Nos. 5,668,239 and 5,739,253, for example. Thefilter cartridge assembly can be produced by immersing an end, or bothends, of the filter medium into a non-foaming reaction mixture that isdeposited in a mold and the reaction mixture hardens about the end(s) ofthe filter medium to thereby affix the end member to an end of the body.

As indicated, certain processes of the present specification comprisedepositing a non-foaming reaction mixture into a mold. As used herein,“non-foaming reaction mixture” means that the reaction mixture does notform a foam when reacted. As used herein, the term “foam” refers to asubstance that is formed by trapping pockets of gas in a liquid orsolid. As such, the reaction mixtures used in certain processes of thepresent specification are substantially free of any blowing agent. Asused herein, the term “substantially free”, when used with reference tothe absence of blowing agent in the reaction mixture, means that thereis insufficient blowing agent in the reaction mixture to result in theproduction of a foam when the reaction mixture is reacted. Examples ofsuch blowing agents are water and readily volatile organic substances,including hydrofluorocarbons, perfluorinated hydrocarbons,polyfluoroalkenes, and hydrocarbons, such as isomers of butane, pentane,cyclopentane, hexane, heptane or diethylether, among others. In certainembodiments, the reaction mixture does not include any intentionallyadded blowing agent, or, in some cases, does not include any blowingagent at all.

In certain embodiments of the processes of the present specification,the non-foaming reaction mixture comprises an organic polyisocyanateprepolymer with an internal mold release agent. Suitable suchpolyisocyanate prepolymers include, but are not necessarily limited to,the reaction products of fatty acid esters and organic polyisocyanates.

Suitable fatty acid esters include, without limitation, those in whichat least one aliphatic acid which contains more than 8 carbon atoms isbuilt into the molecule and which have acid numbers of between 0 and100, such as between 0 and 40, and hydroxyl numbers between 0 and 150,such as between 0 and 75, with at least one of the acid number andhydroxyl number being greater than 0.

Suitable fatty acid esters include polyesters or mixed esters preparedboth from monofunctional and from polyfunctional carboxylic acids and/oralcohols, including fatty acid esters prepared from several differenttypes of fatty acids or carboxylic acids and/or alcohols so thatcomplicated fatty acid esters with a number average molecular weight of,for example, 500 to 5000 grams/mole, such as 800 to 3000 grams/mole, areobtained.

Amines or amino alcohols may also be used in the preparation of thefatty acid esters to produce fatty acid mixed esters which contain basicor amide groups, which are suitable for use in the processes of thepresent specification. Such mixed esters can be obtained, for example,by adding ammonia, monoalkylamines or dialkylamines or theiralkoxylation products, for example with ethylene oxide, propylene oxideor higher epoxides or by using acid amides which contain carboxyl groupsor alcohol groups. These acid amides may be obtained, for example, bythe amidation of carboxylic acids with monoalkanolamines ordialkanolamines such as ethanolamine, diethanolamine, propanolamine, ordipropanolamine, among others.

In some embodiments, the fatty acid esters used for the reaction withthe polyisocyanates are prepared by esterifying carboxylic acids withalcohols. Suitable alcohols include, but are not limited to, butanol,hexanol, octanol-isomers, dodecanol, oleyl alcohol, natural or syntheticsteroid alcohols, ethylene glycol, propylene glycol, butanediols,hexanediols, glycerol, trimethylolpropane, pentaerythritol, sorbitol,hexitol, various sugars, as well as addition products of alkyleneoxides, such as ethylene oxide or propylene oxide, with these alcohols,and the like, including mixtures of any of the foregoing. In some cases,the alcohol comprises glycerol, trimethylolpropane, pentaerythritol,sorbitol, or any mixture of any two or more thereof.

The carboxylic acids used may be saturated or unsaturated and are, insome cases, aliphatic, for example octane carboxylic acids, dodecaneacids, natural fatty acids, such as ricinoleic acid, oleic acid, elaidicacid, stearic acid, palmitic acid, linoleic acid, linolenic acid acid,train oil fatty acids, fatty acids obtained from coconut oil, tallowfatty acids or fatty acids obtained by paraffin oxidation, tall oilfatty acids, succinic acid, maleic acid, citric acid, azelaic acid,adipic acid or higher dicarboxylic and polycarboxylic acids,oligomerisation products of unsaturated carboxylic acids and additionproducts of maleic acid with natural and synthetic oils, and the like.In some cases, the carboxylic acid comprises oleic acid, linoleic acid,ricinoleic acid, adipic acid, or a mixture of any two or more thereof.

In some cases, the fatty acid esters are prepared by cocondensation ofthe alcohols and acids at a temperatures above 100° C., such as 120° to180° C., optionally in a vacuum, the process of the elimination of waterbeing continued until the desired hydroxyl and acid numbers or averagemolecular weights have been obtained. The process of esterification may,if desired, be catalyzed with acid or basic catalysts and the water maybe eliminated by azeotropic distillation. The products prepared maycontain hydroxyl and/or carboxylic acid groups.

In certain embodiments, the fatty acid ester used is a condensate ofoleic acid with a dicarboxylic acid, such as adipic acid, and apolyfunctional alcohol, such as pentaerythritol, that has a numberaverage molecular weight of 900 to 2500 gram/mole, a hydroxyl number of30 to 70 mg KOH/gram, and/or an acid number of 3 to 30 determinedaccording to DIN EN ISO 2114 (June 2002).

Any of a variety of organic polyisocyanates, including aliphatic,cycloaliphatic, araliphatic, aromatic and/or heterocyclicpolyisocyanates, may be used for the reaction with the fatty acid esterto make the organic polyisocyanate prepolymer with an internal moldrelease agent suitable for use in processes of the presentspecification. Specific examples of which include, but are not limitedto, ethylene diisocyanate, tetramethylene-1,4-diisocyanate,hexamethylene-1,6-diisocyanate, dodecane-1,12-diisocyanate,cyclobutane-1,3-diisocyanate, cyclohexane-1,3-diisocyanate,cyclohexane-1,4-diisocyanate,1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane,hexahydrotolylene-2,4-diisocyanate, hexahydrotolylene-2,6-diisocyanate,hexahydrophenylene-1,3-diisocyanate,hexahydrophenylene-1,4-diisocyanate,perhydrodiphenylmethane-1,4′-diisocyanate,perhydrodiphenylmethane-4,4′-diisocyanate, phenylene-1,3-diisocyanate,phenylene-1,4-diisocyanate, tolylene-2,4-diisocyanate,tolylene-2,6-diisocyanate, diphenylmethane-2,4′-diisocyanate,diphenylmethane-4,4′-diisocyanate, naphthylene-1,5-diisocyanate,triphenylmethane-4,4′,4″-triisocyanate, polyphenyl-polymethylenepolyisocyanates obtained by aniline-formaldehyde condensation followedby phosgenation, polyisocyanates which contain carbodiimide groups,polyisocyanates which contain allophanate groups, polyisocyanates whichcontain isocyanurate groups, polyisocyanates which contain urethanegroups, polyisocyanates which contain acylated urea groups,polyisocyanates which contain biuret groups, polyisocyanates whichcontain ester groups, and any mixtures of two or more of any of theforegoing.

Reaction of the fatty acid ester or mixtures of fatty acid esters withthe polyisocyanates can be carried out by mixing the fatty acid esterwith the polyisocyanate and reacting the components at temperatures of,for example, 30° C. to 200° C., such as 45° C. to 95° C., with stirring.

The molar ratio of active hydrogen atoms to isocyanate groups in thereaction of the fatty acid ester with the polyisocyanate is, in certainembodiments, from 1:1 to 1:25. In certain embodiments, a mixture of 0.5to 50% by weight, such as 1 to 35% by weight, of fatty acid esters and99.5 to 50% by weight, such as 99 to 65% by weight of polyisocyanate(the weight percents being based on the total weight of fatty acid esterand polyisocyanate) are reacted at a temperature of 30° C. to 200° C. Incertain embodiments, the quantity of fatty acid ester used is from 0.5to 25% by weight, such as 2 to 18% by weight, based on the total weightof polyisocyanate.

As illustrated in the Examples below, the extent of mold releaseperformance in a non-foam elastomer, when using such polyisocyanateprepolymers that are the reaction product of a fatty acid ester andorganic polyisocyanates, was far greater than expected.

As previously indicated, in the processes of the present specification,the non-foaming reaction mixture comprises an isocyanate-reactivecomposition. As used herein, the term “isocyanate-reactive composition”refers to a composition comprising one or more ingredients withfunctional groups reactive with isocyanate groups, examples of suchgroups being amine groups, thiol groups, and hydroxyl groups. In theprocesses of the present specification, the isocyanate-reactivecomposition comprises one or more polyols.

More particularly, a critical aspect of the isocyanate-reactivecomposition used in the processes of the present specification is theuse of an isocyanate-reactive composition comprising 1% to 10% byweight, based on the total weight of isocyanate-reactive ingredients inthe isocyanate-reactive composition, of a polyether tetrol that is analkylene diamine-alkylene oxide adduct having a number average molecularweight of 150 to 500 gram/mole, such as 300 to 400 gram/mole, or 340 to380 gram/mole, such as those having a hydroxyl number of 600 to 660 mgKOH/g. In fact, as illustrated in the Examples, it was discovered thatthe presence of such an adduct, in the right amount, was essential toprovide an elastomer having sufficient hardness as well as an adequatecure profile to maintain manufacturing productivity. In certainembodiments of the processes of the present specification, the foregoingadduct is present in an amount of 2% to 6% by weight, based on the totalweight of isocyanate-reactive ingredients in the isocyanate-reactivecomposition.

Alkylene diamines suitable for use in preparing the foregoing adductinclude those of the formula:

H₂N—R—NH₂

where R is a C₂ to C₈ straight or branched chain alkylene group.Specific examples of suitable diamines include ethylene diamine and thevarious straight and branched chain isomers of diaminopropane,diaminobutane, diaminopentane, diaminohexane, diaminoheptane, anddiaminooctane. Specific examples include 1,2- and 1,3-diaminopropane,1,3-, 2,3-, and 1,4-diaminobutane, 1,2-diamino-2-methyl propane,1,5-diaminopentane, 1,4-diamino-1-methylbutane,1,4-diamino-2-methylbutane, 1,3-diamino-1-ethylpropane,1,3-diamino-1,1-dimethylpropane, 1,3-diamino-1,2-dimethylpropane,1,3-diamino-2,2-dimethylpropane, 1,5-diamino-2-methylpentane, and/or1,6-diaminohexane. The adducts useful herein can be prepared by reactingone or more of the above noted diamines with one or more alkyleneoxides, such as ethylene oxide and/or propylene oxide. Suitable adductscan be prepared by reacting one mole of the diamine with from 4 to 12moles, such as 4 to 6 moles, or 4 or 5 moles, of the alkylene oxide.

In certain embodiments of the processes of the present specification,the isocyanate-reactive composition further comprises a polyether polyolprepared from an initiator which is not an amine (e.g., any of the knownhydroxyl group-containing starters) that has a hydroxyl functionality ofgreater than 2, such as 3 or more, such as 3 to 4, or 3, and a numberaverage molecular weight of 150 to 500 gram/mole, such as 150 to 450gram/mole, such as 240 to 300 gram/mole, such as those having afunctionality of 3 and a hydroxyl number of 350 to 660 mg KOH/g, such as600 to 660 mg KOH/g or 640 to 660 mg KOH/g.

In some embodiments of the processes of the present specification, thepolyether polyol prepared from an initiator which is not an amine (A)and the alkylene diamine-alkylene oxide adduct (B) are present in theisocyanate-reactive composition in a relative ratio, by weight of(A):(B), of at least 1:1, such as at least 2:1 or, in some cases, 2:1 to4:1. In addition, in some embodiments, the combined weight of thepolyether polyol prepared from an initiator which is not an aminedescribed above and the alkylene diamine-alkylene oxide adduct describedabove in the isocyanate-reactive composition is at least 10 percent byweight, such as 10 to 20 percent by weight, based on the total weight ofthe isocyanate-reactive composition.

In addition, in some embodiments of the processes of the presentspecification, the isocyanate-reactive composition further comprises apolyether polyol having a hydroxyl functionality of at least 2,sometimes greater than 2 and a number average molecular weight of fromabove 500 gram/mole to below 2000 gram/mole or from 600 gram/mole to 800gram/mole. In certain embodiments, such polyether polyols are thereaction product of one or more alkylene oxides and an aliphatic dioland/or triol, optionally in combination with pentaerythritol, water, andmixtures of two or more of any of the foregoing. Suitable aliphatictriols include, but are not limited to, trimethylolethane,trimethylolpropane, triethylolpropane, 1,2,6-hexane triol, and mixturesof two or more of any of the foregoing. Suitable aliphatic diolsinclude, but are not limited to, ethylene glycol, propylene glycol,1,3-butylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, glycerol,and mixtures of two or more of any of the foregoing. Suitable alkyleneoxides include, but are not limited to, ethylene oxide, propylene oxide,butylene oxide, and mixtures of two or more of any of the foregoing.

In certain embodiments, the foregoing polyether polyol having a hydroxylfunctionality of at least 2, such as greater than 2, and a numberaverage molecular weight of from above 500 to below 2000 gram/mole, ispresent in an amount of 40 to 80 percent by weight, such as 50 to 70percent by weight, based on the total weight of the isocyanate-reactivecomposition. In certain embodiments, the isocyanate-reactive compositioncomprises a blend of polyols that comprises (i) 60 to 90% by weight,such as 70 to 90% by weight, such as 75 to 85% by weight, of polyol(s)having a hydroxyl functionality of at least 2, such as greater than 2,and a number average molecular weight of from above 500 to below 2000gram/mole; (ii) 10 to 40% by weight, such as 15 to 25% by weight, ofpolyol(s) having a hydroxyl functionality of greater than 2 and a numberaverage molecular weight of 150 to 500 gram/mole, such weight percentsbeing based on the total weight of polyols in the isocyanate-reactivecomposition.

It was discovered that merely replacing the organic polyisocyanateprepolymer with an organic polyisocyanate prepolymer having an internalmold release agent, without modifying the components of theisocyanate-reactive composition, could not satisfy the objective ofeliminating the need to apply an external mold release agent to the moldprior to production of each, or nearly each elastomer, such as a filterend-cap, while still providing filter end-caps exhibiting requiredphysical properties, such as hardness sufficient for use with filtersused in swimming pool and spa applications, all without negativelyimpacting manufacturing productivity. In particular, in order to solvesuch a problem in the processes of the present specification, it wasdiscovered that to provide a polyurethane elastomer having a Shore Dhardness measured within 10 minutes after production that is at least60% of the Shore D hardness of the polyurethane elastomer measured 16hours after production, more particularly in some cases, wherein theelastomer has a Shore D hardness of at least 80 measured 16 hours afterproduction and the Shore D hardness within 10 minutes after productionis at least 80% of the Shore D hardness of the polyurethane elastomermeasured 16 hours after production, it was critical to use anisocyanate-reactive composition comprising 1% to 10% by weight, such as2% to 6% by weight, based on the total weight of isocyanate-reactiveingredients in the isocyanate-reactive composition, of a polyethertetrol that is an alkylene diamine-alkylene oxide adduct having a numberaverage molecular weight of 150 to 500 gram/mole, such as 300 to 400gram/mole, or 340 to 380 gram/mole, such as those having a hydroxylnumber of 600 to 660 mg KOH/g. The Shore D hardness values reportedherein are determined according to ASTM D2240-15.

Moreover, as indicated earlier, in some cases it is desired to providesuch compositions that can produce a molded polyurethane elastomerexhibiting a final Shore D hardness (16 hours after production) of atleast 80 or more. As a result, embodiments of the present disclosure arealso directed to producing such elastomers by depositing a non-foamingreaction mixture into a mold, the non-foaming reaction mixturecomprising: (a) an organic polyisocyanate prepolymer having an internalmold release agent; and (b) an isocyanate-reactive compositioncomprising: (i) 1% to 10% by weight, based on the total weight ofisocyanate-reactive ingredients in the isocyanate-reactive composition,of a polyether tetrol that is an alkylene diamine-alkylene oxide adducthaving a number average molecular weight of 150 to 500 gram/mole; (ii) apolyether polyol prepared from an initiator which is not an amine thathas a hydroxyl functionality greater than 2 and a number averagemolecular weight of 150 to 500 gram/mole; and (iii) 40 to 80 percent byweight, based on the total weight of the isocyanate-reactivecomposition, of a polyether polyol having a functionality of 3 and anumber average molecular weight of 600 to 800 gram/mole, wherein thepolyether tetrol (i) and the polyether polyol prepared from an initiatorwhich is not an amine (ii) are present in the isocyanate-reactivecomposition in a relative weight ratio of 2:1 to 4:1.

Furthermore, in some embodiments, the isocyanate-reactive compositionhas an average hydroxyl number of greater than 500, in some casesgreater than 550, or greater than 600, and no more than 1000, no morethan 800 or no more than 700. In some embodiments, theisocyanate-reactive composition comprises less than 0.1% by weight, suchas less than 0.05% by weight, or 0% by weight, of carboxylic acid. Incertain embodiments, the isocyanate-reactive composition comprises lessthan 0.5% by weight, such as less than 0.1% by weight, or 0% by weight,of zinc carboxylate, such as a zinc carboxylate containing from 8 to 24carbon atoms per carboxylate group. In certain embodiments, theisocyanate-reactive composition comprises less than 2% by weight, suchas less than 1% by weight, or 0% by weight, of fatty acid. In certainembodiments, the reaction mixture comprises less than 0.5% by weight,such as less than 0.1% by weight, or 0% by weight, of a peralkylatedpolyalkylene polyamine. In certain embodiments, the isocyanate-reactivecomposition does not include a polyether having at least twoisocyanate-reactive groups and a molecular weight of 1800 to 12,000 inwhich at least 50% of the isocyanate-reactive groups are primary amineand/or secondary amino groups. In certain embodiments, theisocyanate-reactive composition comprises less than 5% by weight, suchas less than 1% by weight, or 0% by weight, of a chain extendercomprising a sterically hindered aromatic diamine.

Other suitable isocyanate-reactive compositions may be used, dependingon the desired physical properties of the resulting elastomer. Onesuitable alternative isocyanate-reactive composition is set forth in theExamples (see Example 6).

With respect to any polyols described herein that are polymers, allmolecular weight values are number average molecular weights, unlessotherwise noted. Such number average molecular weights are determined bygel-permeation chromatography (GPC) using a method based on DIN 55672-1employing chloroform as the eluent with a mixed bed column (Agilent PLGel; SDVB; 3 micron Pore dia: 1×Mixed-E+5 micron Pore dia: 2×Mixed-D),refractive index (RI) detection and calibrated with polyethylene glycol.The viscosity of any polyols described herein is determined using anAnton-Paar SVM 3000 viscometer at 25° C. that has been demonstrated togive equivalent results as can be generated with ASTM-D4878-15,calibrating the instrument using mineral oil reference standards ofknown viscosity. The hydroxyl number of any polyols described herein isdetermined according to ASTM D4274-11 and is reported in mg [KOH]/g[polyol].

In addition to the isocyanate-reactive components, theisocyanate-reactive composition may comprise other ingredients, such asfillers, colorants, catalysts, surface-active additives, rheologymodifiers, moisture scavengers, including mixtures of any two or morethereof. Suitable fillers include talc, calcium carbonate, bariumsulfate, fumed or precipitated silica, quartz flour, diatomaceous earth,alumina trihydrate, titanium dioxide, and mixtures of two or more of anyof the foregoing. In some embodiments, the filler is present in anamount of 5 to 50% by weight, such as 10 to 40% by weight or 15 to 30%by weight, based on the total weight of the isocyanate-reactivecomposition.

In certain embodiments, the isocyanate-reactive composition does notinclude an internal mold release agent.

Suitable catalysts include, for example, tertiary amines, such astriethylamine, tributylamine, N-methylmorpholine, N-ethylmorpholine,N-cocomorpholine, N,N,N′,N″-tetramethylethylene diamine,1,4-diazabicyclo-(2,2,2)-octane, N-methyl-N′-dimethylaminoethylpiperazine, N,N-dimethylbenzylamine,bis-(N,N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine,pentamethyldiethylene triamine, N,N-dimethylcyclohexylamine,N,N,N′,N′-tetramethyl-1,3-butane diamine, N,N-dimethyl-phenylethylamine,1,2-dimethylimidazole and 2-methylimidazole. Organometallic compounds,such as organotin compounds, may also be used as catalysts, specificexamples of which include tin-(II)-salts of carboxylic acids, such astin-(II)-acetate, tin-(II)-octoate, tin-(II)-ethylhexoate andtin-(II)-laurate and the dialkyl tin salts of carboxylic acids, such asdibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin maleate ordioctyl tin diacetate. These polyurethane catalysts are generallyincluded in the isocyanate-reactive composition in an amount of from0.01 to 5 parts by weight, such as from 0.02 to 1 parts by weight, basedon total weight of the polyol in the isocyanate-reactive composition.

As indicated earlier, some embodiments of the processes of the presentspecification comprise depositing a non-foaming reaction mixture into amold by mixing an isocyanate functional component as described hereinand an isocyanate-reactive composition and injecting the mixture into amold. In some embodiments, the isocyanate functional component and theisocyanate-reactive composition are mixed at an isocyanate index of from90 to 140, such as 100 to 120.

The reaction mixtures and processes described herein can be particularlysuitable for producing filter cartridge assemblies. As a result, someembodiments of the processes of the present specification are directedto making a filter cartridge assembly. These processes comprise affixingan end member to at least one end of a body comprising a filter medium,wherein the end member is a polyurethane elastomer that is the reactionproduct of a non-foaming reaction mixture comprising anisocyanate-reactive composition and an organic polyisocyanate prepolymerwith an internal mold release agent, such as any of the reactionmixtures described above in this specification. The filter cartridgeassembly can be produced by immersing an end, or both ends, of thefilter medium into a non-foaming reaction mixture that is deposited in amold wherein the reaction mixture hardens about the end(s) of the filtermedium to form the end cap(s). These processes of the present invention,in certain embodiments, do not include the use of an external moldrelease agent applied to the mold surfaces.

Various aspects of the subject matter described in this specificationare set out in the following embodiments:

Embodiment 1

A process of making a filter cartridge assembly comprising an end memberand a body comprising a filter medium, comprising affixing the endmember to an end of the body, wherein the end member is a polyurethaneelastomer that is a reaction product of a non-foaming reaction mixturecomprising an isocyanate-reactive composition and an organicpolyisocyanate prepolymer having an internal mold release agent, whereinthe isocyanate-reactive composition comprises 1% to 10% by weight, basedon the total weight of isocyanate-reactive ingredients in theisocyanate-reactive composition, of a polyether tetrol that is analkylene diamine-alkylene oxide adduct having a number average molecularweight of 150 to 500 gram/mole.

Embodiment 2

The process of Embodiment 1, wherein the filter medium is a pleatedmaterial, such as a spun bonded polyester, polypropylene or cotton.

Embodiment 3

The process of one or more of Embodiment 1 to Embodiment 2, wherein thebody has a generally cylindrical structure and/or the end member isgenerally circular.

Embodiment 4

The process of one or more of Embodiment 1 to Embodiment 3, wherein theaffixing comprises depositing the non-foaming reaction mixture into amold, such as by a one-shot technique in which the organicpolyisocyanate prepolymer and the isocyanate-reactive composition areseparately supplied to a mixhead, where they are mixed, and the mixtureis then injected into a mold and an end of the filter medium is immersedinto the non-foaming reaction mixture that is deposited in the molduntil the reaction mixture hardens about the end of the filter medium.

Embodiment 5

The process of one or more of Embodiment 1 to Embodiment 4, wherein theorganic polyisocyanate prepolymer with an internal mold release agentcomprises a reaction product of a fatty acid ester and an organicpolyisocyanate, such as a fatty acid ester in which at least onealiphatic acid which contains more than 8 carbon atoms is built into themolecule and which has an acid number of between 0 and 100, such asbetween 0 and 40, and a hydroxyl number between 0 and 150, such asbetween 0 and 75, with at least one of the acid number and hydroxylnumber being greater than 0.

Embodiment 6

The process of Embodiment 5, wherein the fatty acid ester has a numberaverage molecular weight of 500 to 5000 grams/mole, such as 800 to 3000grams/mole.

Embodiment 7

The process of one or more of Embodiment 5 to Embodiment 6, wherein thefatty acid ester is a condensate of oleic acid with a dicarboxylic acid,such as adipic acid, and a polyfunctional alcohol, such aspentaerythritol, and has a number average molecular weight of 900 to2500 gram/mole, a hydroxyl number of 30 to 70 mg KOH/gram, and/or anacid number of 3 to 30 determined according to DIN EN ISO 2114 (June2002).

Embodiment 8

The process of one or more of Embodiment 5 to Embodiment 7, wherein theorganic polyisocyanate used for the reaction with the fatty acid esterto make the organic polyisocyanate prepolymer with an internal moldrelease agent comprises ethylene diisocyanate,tetramethylene-1,4-diisocyanate, hexamethylene-1,6-diisocyanate,dodecane-1,12-diisocyanate, cyclobutane-1,3-diisocyanate,cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate,1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane,hexahydrotolylene-2,4-diisocyanate, hexahydrotolylene-2,6-diisocyanate,hexahydrophenylene-1,3-diisocyanate,hexahydrophenylene-1,4-diisocyanate,perhydrodiphenylmethane-1,4′-diisocyanate,perhydrodiphenylmethane-4,4′-diisocyanate, phenylene-1,3-diisocyanate,phenylene-1,4-diisocyanate, tolylene-2,4-diisocyanate,tolylene-2,6-diisocyanate, diphenylmethane-2,4′-diisocyanate,diphenylmethane-4,4′-diisocyanate, naphthylene-1,5-diisocyanate,triphenylmethane-4,4′,4″-triisocyanate, a polyphenyl-polymethylenepolyisocyanate obtained by aniline-formaldehyde condensation followed byphosgenation, a polyisocyanate which contains carbodiimide groups, apolyisocyanate which contains allophanate groups, a polyisocyanate whichcontains isocyanurate groups, a polyisocyanate which contains urethanegroups, a polyisocyanate which contains acylated urea groups, apolyisocyanate which contains biuret groups, a polyisocyanate whichcontains ester groups; or any mixture of two or more of any of theforegoing.

Embodiment 9

The process of one or more of Embodiment 5 to Embodiment 8, whereinfatty acid ester and the polyisocyanate are reacted in amounts such thatthe molar ratio of active hydrogen atoms to isocyanate groups is from1:1 to 1:25.

Embodiment 10

The process of one or more of Embodiment 5 to Embodiment 9, wherein amixture of 0.5 to 50% by weight, such as 1 to 35% by weight, of fattyacid ester and 99.5 to 50% by weight, such as 99 to 65% by weight, ofpolyisocyanate (the weight percents being based on the total weight offatty acid ester and polyisocyanate) are reacted, such as where thequantity of fatty acid ester used is from 0.5 to 25% by weight, such as2 to 18% by weight, based on the total weight of polyisocyanate.

Embodiment 11

The process of one or more of Embodiment 1 to Embodiment 10, wherein thealkylene diamine-alkylene oxide adduct has a number average molecularweight of 300 to 400 gram/mole, such as 340 to 380 gram/mole, and/or hasa hydroxyl number of 600 to 660 mg KOH/g.

Embodiment 12

The process of one or more of Embodiment 1 to Embodiment 11, wherein thealkylene diamine-alkylene oxide adduct is present in an amount of 2% to6% by weight, based on the total weight of isocyanate-reactiveingredients in the isocyanate-reactive composition.

Embodiment 13

The process of one or more of Embodiment 1 to Embodiment 12, wherein thealkylene diamine used to prepare the alkylene diamine-alkylene oxideadduct comprises ethylene diamine.

Embodiment 14

The process of one or more of Embodiment 1 to Embodiment 13, wherein thealkylene oxide used to prepare the alkylene diamine-alkylene oxideadduct comprises ethylene oxide and/or propylene oxide.

Embodiment 15

The process of one or more of Embodiment 1 to Embodiment 14, wherein thealkylene diamine-alkylene oxide adduct is a reaction product of one moleof the diamine with from 4 to 12 moles, such as 4 to 6 moles, or 4 or 5moles, of the alkylene oxide.

Embodiment 16

The process of one or more of Embodiment 1 to Embodiment 15, wherein theisocyanate-reactive composition further comprises a polyether polyolprepared from an initiator which is not an amine that has a hydroxylfunctionality of greater than 2, such as 3 or more, such as 3 to 4, or3, and a number average molecular weight of 150 to 500 gram/mole, suchas 150 to 450 gram/mole, such as 240 to 300 gram/mole, such as thosehaving a functionality of 3 and a hydroxyl number of 350 to 660 mgKOH/g, such as 600 to 660 mg KOH/g or 640 to 660 mg KOH/g.

Embodiment 17

The process of Embodiment 16, wherein the polyether polyol prepared froman initiator which is not an amine (A) and the alkylene diamine-alkyleneoxide adduct (B) are present in the isocyanate-reactive composition in arelative ratio, by weight of (A): (B), of at least 1:1, such as at least2:1 or, in some cases, 2:1 to 4:1.

Embodiment 18

The process of one or more of Embodiment 16 or Embodiment 17, whereinthe combined weight of the polyether polyol prepared from an initiatorwhich is not an amine and the alkylene diamine-alkylene oxide adduct inthe isocyanate-reactive composition is at least 10 percent by weight,such as 10 to 20 percent by weight, based on the total weight of theisocyanate-reactive composition.

Embodiment 19

The process of one or more of Embodiment 1 to Embodiment 18, wherein theisocyanate-reactive composition further comprises a polyether polyolhaving a hydroxyl functionality of at least 2, such as greater than 2,and a number average molecular weight of from above 500 gram/mole tobelow 2000 gram/mole, such as from 600 gram/mole to 800 gram/mole.

Embodiment 20

The process of Embodiment 19, wherein the polyether polyol having ahydroxyl functionality of at least 2 and a number average molecularweight of from above 500 to below 2000 gram/mole is present in an amountof 40 to 80 percent by weight, such as 50 to 70 percent by weight, basedon the total weight of the isocyanate-reactive composition.

Embodiment 21

The process of one or more of Embodiment 1 to Embodiment 20, wherein theisocyanate-reactive composition comprises a blend of polyols thatcomprises (i) 60 to 90% by weight, such as 70 to 90% by weight, such as75 to 85% by weight, of polyol(s) having a hydroxyl functionality of atleast 2, such as greater than 2, and a number average molecular weightof from above 500 to below 2000 gram/mole; and (ii) 10 to 40% by weight,such as 15 to 25% by weight, of polyol(s) having a hydroxylfunctionality of greater than 2 and a number average molecular weight of150 to 500 gram/mole, such weight percents being based on the totalweight of polyols in the isocyanate-reactive composition.

Embodiment 22

The process of one or more of Embodiment 1 to Embodiment 21, wherein thepolyurethane elastomer has a Shore D hardness measured within 10 minutesafter production that is at least 60% of the Shore D hardness of thepolyurethane elastomer measured 16 hours after production, such as wherethe elastomer has a Shore D hardness of at least 80 measured 16 hoursafter production and the Shore D hardness within 10 minutes afterproduction is at least 80% of the Shore D hardness of the polyurethaneelastomer measured 16 hours after production.

Embodiment 23

The process of one or more of Embodiment 1 to Embodiment 22, wherein theisocyanate-reactive composition has an average hydroxyl number ofgreater than 500, in some cases greater than 550, or greater than 600,and no more than 1000, no more than 800 or no more than 700.

Embodiment 24

The process of one or more of Embodiment 1 to Embodiment 23, wherein theisocyanate-reactive composition comprises less than 0.1% by weight, suchas less than 0.05% by weight, or 0% by weight, of carboxylic acid.

Embodiment 25

The process of one or more of Embodiment 1 to Embodiment 24, wherein theisocyanate-reactive composition comprises less than 0.5% by weight, suchas less than 0.1% by weight, or 0% by weight, of zinc carboxylate, suchas a zinc carboxylate containing from 8 to 24 carbon atoms percarboxylate group.

Embodiment 26

The process of one or more of Embodiment 1 to Embodiment 25, wherein theisocyanate-reactive composition comprises less than 2% by weight, suchas less than 1% by weight, or 0% by weight, of fatty acid.

Embodiment 27

The process of one or more of Embodiment 1 to Embodiment 26, wherein thereaction mixture comprises less than 0.5% by weight, such as less than0.1% by weight, or 0% by weight, of a peralkylated polyalkylenepolyamine.

Embodiment 28

The process of one or more of Embodiment 1 to Embodiment 27, wherein theisocyanate-reactive composition does not include a polyether having atleast two isocyanate-reactive groups and a molecular weight of 1800 to12,000 in which at least 50% of the isocyanate-reactive groups areprimary amine and/or secondary amino groups.

Embodiment 29

The process of one or more of Embodiment 1 to Embodiment 28, wherein theisocyanate-reactive composition comprises less than 5% by weight, suchas less than 1% by weight, or 0% by weight, of a chain extendercomprising a sterically hindered aromatic diamine.

Embodiment 30

The process of one or more of Embodiment 1 to Embodiment 29, wherein theisocyanate-reactive composition comprises a filler, such as talc,calcium carbonate, barium sulfate, fumed or precipitated silica, quartzflour, diatomaceous earth, alumina trihydrate, titanium dioxide, andmixtures of two or more of any of the foregoing, such as any of thesewhere the filler is present in an amount of 5 to 50% by weight, such as10 to 40% by weight or 15 to 30% by weight, based on the total weight ofthe isocyanate-reactive composition.

Embodiment 31

The process of one or more of Embodiment 1 to Embodiment 30, wherein theisocyanate-reactive composition does not include an internal moldrelease agent.

Embodiment 32

The process of one or more of Embodiment 1 to Embodiment 31, wherein theisocyanate-reactive composition further comprises a catalyst, such as atertiary amine, such as triethylamine, tributylamine,N-methylmorpholine, N-ethylmorpholine, N-cocomorpholine,N,N,N′,N″-tetramethylethylene diamine, 1,4-diazabicyclo-(2,2,2)-octane,N-methyl-N′-dimethylaminoethyl piperazine, N,N-dimethylbenzylamine,bis-(N,N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine,pentamethyldiethylene triamine, N,N-dimethylcyclohexylamine,N,N,N′,N′-tetramethyl-1,3-butane diamine, N,N-dimethyl-phenylethylamine,1,2-dimethylimidazole and/or 2-methylimidazole, and/or an organometalliccompound, such as an organotin compound, such as tin-(II)-salts ofcarboxylic acids, such as tin-(II)-acetate, tin-(II)-octoate,tin-(II)-ethylhexoate and tin-(II)-laurate and the dialkyl tin salts ofcarboxylic acids, such as dibutyl tin diacetate, dibutyl tin dilaurate,dibutyl tin maleate or dioctyl tin diacetate, including where thecatalyst is included in the isocyanate-reactive composition in an amountof from 0.01 to 5 parts by weight, such as from 0.02 to 1 parts byweight, based on total weight of the polyol in the isocyanate-reactivecomposition.

Embodiment 33

The process of one or more of Embodiment 1 to Embodiment 32 wherein theisocyanate functional component and the isocyanate-reactive compositionare mixed at an isocyanate index of from 90 to 140, such as 100 to 120.

Embodiment 34

A process for producing a molded polyurethane elastomer, comprisingdepositing a non-foaming reaction mixture into a mold, the non-foamingreaction mixture comprising: (a) an organic polyisocyanate prepolymerhaving an internal mold release agent; and (b) an isocyanate-reactivecomposition comprising: (i) 1% to 10% by weight, based on the totalweight of isocyanate-reactive ingredients in the isocyanate-reactivecomposition, of a polyether tetrol that is an alkylene diamine-alkyleneoxide adduct having a number average molecular weight of 150 to 500gram/mole; (ii) a polyether polyol prepared from an initiator which isnot an amine that has a hydroxyl functionality greater than 2 and anumber average molecular weight of 150 to 500 gram/mole; and (iii) 40 to80 percent by weight, such as 50 to 70 percent by weight, based on thetotal weight of the isocyanate-reactive composition, of a polyetherpolyol having a functionality of 3 and a number average molecular weightof 600 to 800 gram/mole, wherein the polyether tetrol (i) and thepolyether polyol prepared from an initiator which is not an amine (ii)are present in the isocyanate-reactive composition in a relative weightratio of 2:1 to 4:1.

Embodiment 35

The process of Embodiment 34, wherein the polyurethane elastomer is anend member of a filter cartridge assembly comprising the end member anda body comprising a filter medium, wherein the process comprisesaffixing the end member to an end of the body.

Embodiment 36

The process of Embodiment 35, wherein the filter medium is a pleatedmaterial, such as a spun bonded polyester, polypropylene or cotton.

Embodiment 37

The process of one or more of Embodiment 35 to Embodiment 36, whereinthe body has a generally cylindrical structure and/or the end member isgenerally circular.

Embodiment 38

The process of one or more of Embodiment 35 to Embodiment 37, wherein anend of the filter medium is immersed into the non-foaming reactionmixture that is deposited in the mold until the reaction mixture hardensabout the end of the filter medium.

Embodiment 39

The process of one or more of Embodiment 34 to Embodiment 38, whereinthe organic polyisocyanate prepolymer with an internal mold releaseagent comprises a reaction product of a fatty acid ester and an organicpolyisocyanate, such as a fatty acid ester in which at least onealiphatic acid which contains more than 8 carbon atoms is built into themolecule and which has an acid number of between 0 and 100, such asbetween 0 and 40, and a hydroxyl number between 0 and 150, such asbetween 0 and 75, with at least one of the acid number and hydroxylnumber being greater than 0.

Embodiment 40

The process of Embodiment 39, wherein the fatty acid ester has a numberaverage molecular weight of 500 to 5000 grams/mole, such as 800 to 3000grams/mole.

Embodiment 41

The process of one or more of Embodiment 39 to Embodiment 40, whereinthe fatty acid ester is a condensate of oleic acid with a dicarboxylicacid, such as adipic acid, and a polyfunctional alcohol, such aspentaerythritol, and has a number average molecular weight of 900 to2500 gram/mole, a hydroxyl number of 30 to 70 mg KOH/gram, and/or anacid number of 3 to 30 determined according to DIN EN ISO 2114 (June2002).

Embodiment 42

The process of one or more of Embodiment 39 to Embodiment 41, whereinthe organic polyisocyanate used for the reaction with the fatty acidester to make the organic polyisocyanate prepolymer with an internalmold release agent comprises ethylene diisocyanate,tetramethylene-1,4-diisocyanate, hexamethylene-1,6-diisocyanate,dodecane-1,12-diisocyanate, cyclobutane-1,3-diisocyanate,cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate,1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane,hexahydrotolylene-2,4-diisocyanate, hexahydrotolylene-2,6-diisocyanate,hexahydrophenylene-1,3-diisocyanate,hexahydrophenylene-1,4-diisocyanate,perhydrodiphenylmethane-1,4′-diisocyanate,perhydrodiphenylmethane-4,4′-diisocyanate, phenylene-1,3-diisocyanate,phenylene-1,4-diisocyanate, tolylene-2,4-diisocyanate,tolylene-2,6-diisocyanate, diphenylmethane-2,4′-diisocyanate,diphenylmethane-4,4′-diisocyanate, naphthylene-1,5-diisocyanate,triphenylmethane-4,4′,4″-triisocyanate, a polyphenyl-polymethylenepolyisocyanate obtained by aniline-formaldehyde condensation followed byphosgenation, a polyisocyanate which contains carbodiimide groups, apolyisocyanate which contains allophanate groups, a polyisocyanate whichcontains isocyanurate groups, a polyisocyanate which contains urethanegroups, a polyisocyanate which contains acylated urea groups, apolyisocyanate which contains biuret groups, a polyisocyanate whichcontains ester groups; or any mixture of two or more of any of theforegoing.

Embodiment 43

The process of one or more of Embodiment 39 to Embodiment 42, whereinfatty acid ester and the polyisocyanate are reacted in amounts such thatthe molar ratio of active hydrogen atoms to isocyanate groups is from1:1 to 1:25.

Embodiment 44

The process of one or more of Embodiment 39 to Embodiment 43, wherein amixture of 0.5 to 50% by weight, such as 1 to 35% by weight, of fattyacid ester and 99.5 to 50% by weight, such as 99 to 65% by weight, ofpolyisocyanate (the weight percents being based on the total weight offatty acid ester and polyisocyanate) are reacted, such as where thequantity of fatty acid ester used is from 0.5 to 25% by weight, such as2 to 18% by weight, based on the total weight of polyisocyanate.

Embodiment 45

The process of one or more of Embodiment 34 to Embodiment 44, whereinthe alkylene diamine-alkylene oxide adduct has a number averagemolecular weight of 300 to 400 gram/mole, such as 340 to 380 gram/mole,and/or has a hydroxyl number of 600 to 660 mg KOH/g.

Embodiment 46

The process of one or more of Embodiment 34 to Embodiment 45, whereinthe alkylene diamine-alkylene oxide adduct is present in an amount of 2%to 6% by weight, based on the total weight of isocyanate-reactiveingredients in the isocyanate-reactive composition.

Embodiment 47

The process of one or more of Embodiment 34 to Embodiment 46, whereinthe alkylene diamine used to prepare the alkylene diamine-alkylene oxideadduct comprises ethylene diamine.

Embodiment 48

The process of one or more of Embodiment 34 to Embodiment 47, whereinthe alkylene oxide used to prepare the alkylene diamine-alkylene oxideadduct comprises ethylene oxide and/or propylene oxide.

Embodiment 49

The process of one or more of Embodiment 34 to Embodiment 48, whereinthe alkylene diamine-alkylene oxide adduct is a reaction product of onemole of the diamine with from 4 to 12 moles, such as 4 to 6 moles, or 4or 5 moles, of the alkylene oxide.

Embodiment 50

The process of one or more of Embodiment 34 to Embodiment 49, whereinthe polyether polyol prepared from an initiator which is not an aminehas a hydroxyl functionality of 3 or more, such as 3 to 4, or 3, and/ora number average molecular weight of 150 to 450 gram/mole, such as 240to 300 gram/mole, such as those having a functionality of 3 and ahydroxyl number of 350 to 660 mg KOH/g, such as 600 to 660 mg KOH/g or640 to 660 mg KOH/g.

Embodiment 51

The process of one or more of Embodiment 34 to Embodiment 50, whereinthe combined weight of the polyether polyol prepared from an initiatorwhich is not an amine and the alkylene diamine-alkylene oxide adduct inthe isocyanate-reactive composition is at least 10 percent by weight,such as 10 to 20 percent by weight, based on the total weight of theisocyanate-reactive composition.

Embodiment 52

The process of one or more of Embodiment 34 to Embodiment 51, whereinthe polyurethane elastomer has a Shore D hardness measured within 10minutes after production that is at least 60% of the Shore D hardness ofthe polyurethane elastomer measured 16 hours after production, such aswhere the elastomer has a Shore D hardness of at least 80 measured 16hours after production and the Shore D hardness within 10 minutes afterproduction is at least 80% of the Shore D hardness of the polyurethaneelastomer measured 16 hours after production.

Embodiment 53

The process of one or more of Embodiment 34 to Embodiment 52, whereinthe isocyanate-reactive composition has an average hydroxyl number ofgreater than 500, in some cases greater than 550, or greater than 600,and no more than 1000, no more than 800 or no more than 700.

Embodiment 54

The process of one or more of Embodiment 34 to Embodiment 53, whereinthe isocyanate-reactive composition comprises less than 0.1% by weight,such as less than 0.05% by weight, or 0% by weight, of carboxylic acid.

Embodiment 55

The process of one or more of Embodiment 34 to Embodiment 54, whereinthe isocyanate-reactive composition comprises less than 0.5% by weight,such as less than 0.1% by weight, or 0% by weight, of zinc carboxylate,such as a zinc carboxylate containing from 8 to 24 carbon atoms percarboxylate group.

Embodiment 56

The process of one or more of Embodiment 34 to Embodiment 55, whereinthe isocyanate-reactive composition comprises less than 2% by weight,such as less than 1% by weight, or 0% by weight, of fatty acid.

Embodiment 57

The process of one or more of Embodiment 34 to Embodiment 56, whereinthe reaction mixture comprises less than 0.5% by weight, such as lessthan 0.1% by weight, or 0% by weight, of a peralkylated polyalkylenepolyamine.

Embodiment 58

The process of one or more of Embodiment 34 to Embodiment 57, whereinthe isocyanate-reactive composition does not include a polyether havingat least two isocyanate-reactive groups and a molecular weight of 1800to 12,000 in which at least 50% of the isocyanate-reactive groups areprimary amine and/or secondary amino groups.

Embodiment 59

The process of one or more of Embodiment 34 to Embodiment 58, whereinthe isocyanate-reactive composition comprises less than 5% by weight,such as less than 1% by weight, or 0% by weight, of a chain extendercomprising a sterically hindered aromatic diamine.

Embodiment 60

The process of one or more of Embodiment 34 to Embodiment 59, whereinthe isocyanate-reactive composition comprises a filler, such as talc,calcium carbonate, barium sulfate, fumed or precipitated silica, quartzflour, diatomaceous earth, alumina trihydrate, titanium dioxide, andmixtures of two or more of any of the foregoing, such as any of thesewhere the filler is present in an amount of 5 to 50% by weight, such as10 to 40% by weight or 15 to 30% by weight, based on the total weight ofthe isocyanate-reactive composition.

Embodiment 61

The process of one or more of Embodiment 34 to Embodiment 60, whereinthe isocyanate-reactive composition does not include an internal moldrelease agent.

Embodiment 62

The process of one or more of Embodiment 34 to Embodiment 61, whereinthe isocyanate-reactive composition further comprises a catalyst, suchas a tertiary amine, such as triethylamine, tributylamine,N-methylmorpholine, N-ethylmorpholine, N-cocomorpholine,N,N,N′,N″-tetramethylethylene diamine, 1,4-diazabicyclo-(2,2,2)-octane,N-methyl-N′-dimethylaminoethyl piperazine, N,N-dimethylbenzylamine,bis-(N,N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine,pentamethyldiethylene triamine, N,N-dimethylcyclohexylamine,N,N,N′,N′-tetramethyl-1,3-butane diamine, N,N-dimethyl-phenylethylamine,1,2-dimethylimidazole and/or 2-methylimidazole, and/or an organometalliccompound, such as an organotin compound, such as tin-(II)-salts ofcarboxylic acids, such as tin-(II)-acetate, tin-(II)-octoate,tin-(II)-ethylhexoate and tin-(II)-laurate and the dialkyl tin salts ofcarboxylic acids, such as dibutyl tin diacetate, dibutyl tin dilaurate,dibutyl tin maleate or dioctyl tin diacetate, including where thecatalyst is included in the isocyanate-reactive composition in an amountof from 0.01 to 5 parts by weight, such as from 0.02 to 1 parts byweight, based on total weight of the polyol in the isocyanate-reactivecomposition.

Embodiment 63

The process of one or more of Embodiment 34 to Embodiment 62 wherein theisocyanate functional component and the isocyanate-reactive compositionare mixed at an isocyanate index of from 90 to 140, such as 100 to 120.

Embodiment 64

A process of making a filter cartridge assembly comprising an end memberand a body comprising a filter medium, comprising affixing the endmember to an end of the body, wherein the end member is a polyurethaneelastomer that is a reaction product of a non-foaming reaction mixturecomprising an isocyanate-reactive composition and an organicpolyisocyanate prepolymer having an internal mold release agent, whereinthe isocyanate-reactive composition comprises a mixture of polyolsformulated to provide a polyurethane elastomer having a Shore Dhardness, measured according to ASTM D2240-15, within 10 minutes afterproduction that is at least 60% of the Shore D hardness of thepolyurethane elastomer measured 16 hours after production.

Embodiment 65

The process of Embodiment 64, wherein the filter medium is a pleatedmaterial, such as a spun bonded polyester, polypropylene or cotton.

Embodiment 66

The process of one or more of Embodiment 64 to Embodiment 65, whereinthe body has a generally cylindrical structure and/or the end member isgenerally circular.

Embodiment 67

The process of one or more of Embodiment 64 to Embodiment 66, whereinthe affixing comprises depositing the non-foaming reaction mixture intoa mold, such as by a one-shot technique in which the organicpolyisocyanate prepolymer and the isocyanate-reactive composition areseparately supplied to a mixhead, where they are mixed, and the mixtureis then injected into a mold and an end of the filter medium is immersedinto the non-foaming reaction mixture that is deposited in the molduntil the reaction mixture hardens about the end of the filter medium.

Embodiment 68

The process of one or more of Embodiment 64 to Embodiment 67, whereinthe organic polyisocyanate prepolymer with an internal mold releaseagent comprises a reaction product of a fatty acid ester and an organicpolyisocyanate, such as a fatty acid ester in which at least onealiphatic acid which contains more than 8 carbon atoms is built into themolecule and which has an acid number of between 0 and 100, such asbetween 0 and 40, and a hydroxyl number between 0 and 150, such asbetween 0 and 75, with at least one of the acid number and hydroxylnumber being greater than 0.

Embodiment 69

The process of Embodiment 68, wherein the fatty acid ester has a numberaverage molecular weight of 500 to 5000 grams/mole, such as 800 to 3000grams/mole.

Embodiment 70

The process of one or more of Embodiment 68 to Embodiment 69, whereinthe fatty acid ester is a condensate of oleic acid with a dicarboxylicacid, such as adipic acid, and a polyfunctional alcohol, such aspentaerythritol, and has a number average molecular weight of 900 to2500 gram/mole, a hydroxyl number of 30 to 70 mg KOH/gram, and/or anacid number of 3 to 30 determined according to DIN EN ISO 2114 (June2002).

Embodiment 71

The process of one or more of Embodiment 68 to Embodiment 70, whereinthe organic polyisocyanate used for the reaction with the fatty acidester to make the organic polyisocyanate prepolymer with an internalmold release agent comprises ethylene diisocyanate,tetramethylene-1,4-diisocyanate, hexamethylene-1,6-diisocyanate,dodecane-1,12-diisocyanate, cyclobutane-1,3-diisocyanate,cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate,1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane,hexahydrotolylene-2,4-diisocyanate, hexahydrotolylene-2,6-diisocyanate,hexahydrophenylene-1,3-diisocyanate,hexahydrophenylene-1,4-diisocyanate,perhydrodiphenylmethane-1,4′-diisocyanate,perhydrodiphenylmethane-4,4′-diisocyanate, phenylene-1,3-diisocyanate,phenylene-1,4-diisocyanate, tolylene-2,4-diisocyanate,tolylene-2,6-diisocyanate, diphenylmethane-2,4′-diisocyanate,diphenylmethane-4,4′-diisocyanate, naphthylene-1,5-diisocyanate,triphenylmethane-4,4′,4″-triisocyanate, a polyphenyl-polymethylenepolyisocyanate obtained by aniline-formaldehyde condensation followed byphosgenation, a polyisocyanate which contains carbodiimide groups, apolyisocyanate which contains allophanate groups, a polyisocyanate whichcontains isocyanurate groups, a polyisocyanate which contains urethanegroups, a polyisocyanate which contains acylated urea groups, apolyisocyanate which contains biuret groups, a polyisocyanate whichcontains ester groups; or any mixture of two or more of any of theforegoing.

Embodiment 72

The process of one or more of Embodiment 68 to Embodiment 71, whereinfatty acid ester and the polyisocyanate are reacted in amounts such thatthe molar ratio of active hydrogen atoms to isocyanate groups is from1:1 to 1:25.

Embodiment 73

The process of one or more of Embodiment 68 to Embodiment 72, wherein amixture of 0.5 to 50% by weight, such as 1 to 35% by weight, of fattyacid ester and 99.5 to 50% by weight, such as 99 to 65% by weight, ofpolyisocyanate (the weight percents being based on the total weight offatty acid ester and polyisocyanate) are reacted, such as where thequantity of fatty acid ester used is from 0.5 to 25% by weight, such as2 to 18% by weight, based on the total weight of polyisocyanate.

Embodiment 74

The process of one or more of Embodiment 64 to Embodiment 73, whereinthe isocyanate-reactive composition comprises 1% to 10% by weight, suchas 2% to 6% by weight, based on the total weight of isocyanate-reactiveingredients in the isocyanate-reactive composition, of a polyethertetrol that is an alkylene diamine-alkylene oxide adduct having a numberaverage molecular weight of 150 to 500 gram/mole, such as 300 to 400gram/mole, such as 340 to 380 gram/mole, and/or has a hydroxyl number of600 to 660 mg KOH/g.

Embodiment 75

The process of Embodiment 74, wherein the alkylene diamine used toprepare the alkylene diamine-alkylene oxide adduct comprises ethylenediamine.

Embodiment 76

The process of one or more of Embodiment 74 to Embodiment 75, whereinthe alkylene oxide used to prepare the alkylene diamine-alkylene oxideadduct comprises ethylene oxide and/or propylene oxide.

Embodiment 77

The process of one or more of Embodiment 74 to Embodiment 76, whereinthe alkylene diamine-alkylene oxide adduct is a reaction product of onemole of the diamine with from 4 to 12 moles, such as 4 to 6 moles, or 4or 5 moles, of the alkylene oxide.

Embodiment 78

The process of one or more of Embodiment 64 to Embodiment 77, whereinthe isocyanate-reactive composition further comprises a polyether polyolprepared from an initiator which is not an amine that has a hydroxylfunctionality of greater than 2, such as 3 or more, such as 3 to 4, or3, and a number average molecular weight of 150 to 500 gram/mole, suchas 150 to 450 gram/mole, such as 240 to 300 gram/mole, such as thosehaving a functionality of 3 and a hydroxyl number of 350 to 660 mgKOH/g, such as 600 to 660 mg KOH/g or 640 to 660 mg KOH/g.

Embodiment 79

The process of Embodiment 78, wherein the polyether polyol prepared froman initiator which is not an amine (A) and the alkylene diamine-alkyleneoxide adduct (B) are present in the isocyanate-reactive composition in arelative ratio, by weight of (A): (B), of at least 1:1, such as at least2:1 or, in some cases, 2:1 to 4:1.

Embodiment 80

The process of one or more of Embodiment 78 or Embodiment 79, whereinthe combined weight of the polyether polyol prepared from an initiatorwhich is not an amine and the alkylene diamine-alkylene oxide adduct inthe isocyanate-reactive composition is at least 10 percent by weight,such as 10 to 20 percent by weight, based on the total weight of theisocyanate-reactive composition.

Embodiment 81

The process of one or more of Embodiment 64 to Embodiment 80, whereinthe isocyanate-reactive composition further comprises a polyether polyolhaving a hydroxyl functionality of at least 2, such as greater than 2,and a number average molecular weight of from above 500 gram/mole tobelow 2000 gram/mole, such as from 600 gram/mole to 800 gram/mole.

Embodiment 82

The process of Embodiment 81, wherein the polyether polyol having ahydroxyl functionality of at least 2 and a number average molecularweight of from above 500 to below 2000 gram/mole is present in an amountof 40 to 80 percent by weight, such as 50 to 70 percent by weight, basedon the total weight of the isocyanate-reactive composition.

Embodiment 83

The process of one or more of Embodiment 64 to Embodiment 82, whereinthe isocyanate-reactive composition comprises a blend of polyols thatcomprises (i) 60 to 90% by weight, such as 70 to 90% by weight, such as75 to 85% by weight, of polyol(s) having a hydroxyl functionality of atleast 2, such as greater than 2, and a number average molecular weightof from above 500 to below 2000 gram/mole; and (ii) 10 to 40% by weight,such as 15 to 25% by weight, of polyol(s) having a hydroxylfunctionality of greater than 2 and a number average molecular weight of150 to 500 gram/mole, such weight percents being based on the totalweight of polyols in the isocyanate-reactive composition.

Embodiment 84

The process of one or more of Embodiment 64 to Embodiment 83, whereinthe elastomer has a Shore D hardness of at least 80 measured 16 hoursafter production and the Shore D hardness within 10 minutes afterproduction is at least 80% of the Shore D hardness of the polyurethaneelastomer measured 16 hours after production.

Embodiment 85

The process of one or more of Embodiment 64 to Embodiment 84, whereinthe isocyanate-reactive composition has an average hydroxyl number ofgreater than 500, in some cases greater than 550, or greater than 600,and no more than 1000, no more than 800 or no more than 700.

Embodiment 86

The process of one or more of Embodiment 64 to Embodiment 85, whereinthe isocyanate-reactive composition comprises less than 0.1% by weight,such as less than 0.05% by weight, or 0% by weight, of carboxylic acid.

Embodiment 87

The process of one or more of Embodiment 64 to Embodiment 86, whereinthe isocyanate-reactive composition comprises less than 0.5% by weight,such as less than 0.1% by weight, or 0% by weight, of zinc carboxylate,such as a zinc carboxylate containing from 8 to 24 carbon atoms percarboxylate group.

Embodiment 88

The process of one or more of Embodiment 64 to Embodiment 87, whereinthe isocyanate-reactive composition comprises less than 2% by weight,such as less than 1% by weight, or 0% by weight, of fatty acid.

Embodiment 89

The process of one or more of Embodiment 64 to Embodiment 88, whereinthe reaction mixture comprises less than 0.5% by weight, such as lessthan 0.1% by weight, or 0% by weight, of a peralkylated polyalkylenepolyamine.

Embodiment 90

The process of one or more of Embodiment 64 to Embodiment 89, whereinthe isocyanate-reactive composition does not include a polyether havingat least two isocyanate-reactive groups and a molecular weight of 1800to 12,000 in which at least 50% of the isocyanate-reactive groups areprimary amine and/or secondary amino groups.

Embodiment 91

The process of one or more of Embodiment 64 to Embodiment 90, whereinthe isocyanate-reactive composition comprises less than 5% by weight,such as less than 1% by weight, or 0% by weight, of a chain extendercomprising a sterically hindered aromatic diamine.

Embodiment 92

The process of one or more of Embodiment 64 to Embodiment 91, whereinthe isocyanate-reactive composition comprises a filler, such as talc,calcium carbonate, barium sulfate, fumed or precipitated silica, quartzflour, diatomaceous earth, alumina trihydrate, titanium dioxide, andmixtures of two or more of any of the foregoing, such as any of thesewhere the filler is present in an amount of 5 to 50% by weight, such as10 to 40% by weight or 15 to 30% by weight, based on the total weight ofthe isocyanate-reactive composition.

Embodiment 93

The process of one or more of Embodiment 64 to Embodiment 92, whereinthe isocyanate-reactive composition does not include an internal moldrelease agent.

Embodiment 94

The process of one or more of Embodiment 64 to Embodiment 93, whereinthe isocyanate-reactive composition further comprises a catalyst, suchas a tertiary amine, such as triethylamine, tributylamine,N-methylmorpholine, N-ethylmorpholine, N-cocomorpholine,N,N,N′,N″-tetramethylethylene diamine, 1,4-diazabicyclo-(2,2,2)-octane,N-methyl-N′-dimethylaminoethyl piperazine, N,N-dimethylbenzylamine,bis-(N,N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine,pentamethyldiethylene triamine, N,N-dimethylcyclohexylamine,N,N,N′,N′-tetramethyl-1,3-butane diamine, N,N-dimethyl-phenylethylamine,1,2-dimethylimidazole and/or 2-methylimidazole, and/or an organometalliccompound, such as an organotin compound, such as tin-(II)-salts ofcarboxylic acids, such as tin-(II)-acetate, tin-(II)-octoate,tin-(II)-ethylhexoate and tin-(II)-laurate and the dialkyl tin salts ofcarboxylic acids, such as dibutyl tin diacetate, dibutyl tin dilaurate,dibutyl tin maleate or dioctyl tin diacetate, including where thecatalyst is included in the isocyanate-reactive composition in an amountof from 0.01 to 5 parts by weight, such as from 0.02 to 1 parts byweight, based on total weight of the polyol in the isocyanate-reactivecomposition.

Embodiment 95

The process of one or more of Embodiment 64 to Embodiment 94 wherein theisocyanate functional component and the isocyanate-reactive compositionare mixed at an isocyanate index of from 90 to 140, such as 100 to 120.

The non-limiting and non-exhaustive examples that follow are intended tofurther describe various non-limiting and non-exhaustive embodimentswithout restricting the scope of the embodiments described in thisspecification.

EXAMPLES

All quantities given in “parts” and “percents” are understood to be byweight, unless otherwise indicated. The following materials were used inthe formulations of the examples:

POLYOL A: A 700 molecular weight polypropylene oxide-based triol;functionality 3; hydroxyl number 233 to 243 mg KOH/g; viscosity of 250cps @ 25° C.

POLYOL B: A 260 molecular weight polypropylene oxide-based triol;functionality 3; hydroxyl number 640 to 660 mg KOH/g; viscosity of 820cps @ 25° C.

POLYOL C: An amine initiated polyether polyol; functionality of 4;hydroxyl number of 600 to 660 mg KOH/g; molecular weight 360; viscosityof 16,000 to 20,000 mPa·s @ 25° C.

POLYOL D: A bifunctional polyether polyol; hydroxyl number of 107.4 to115.4 mg KOH/g; molecular weight 1000; viscosity of 135 to 175 mPa·s @25° C.

POLYOL E: A bifunctional polyether polyol; hydroxyl number of 54.7 to57.5 mg KOH/g; molecular weight 2000; viscosity of 325 to 365 mPa·s @25° C.

POLYOL F: A 450 molecular weight polypropylene oxide-based triol;functionality 3; hydroxyl number 350 to 390 mg KOH/g; viscosity of 520to 700 mPa·s @ 25° C.

FILLER 1: Ground calcium carbonate commercially available from HuberEngineered Materials as Hubercarb® Q6.

FILLER 2: Kaolin clay commercially available from BASF as Satintone®SP-33.

PIGMENT 1: Carbon black pigment commercially available from RockwoodPigments.

PIGMENT 2: Blue pigment commercially available from Polyone Corp.(Stan-Tone HCC33598 Blue).

BYK 410: Rheology additive commercially available from BYK Alatana Group

DABCO T-12: Tin catalyst commercially available from Air Products &Chemicals

UOP L: moisture scavenger—a potassium calcium sodium aluminosilicate ofthe zeolite A type commercially available from A.B. Colby, Inc.

ISO A: an MDI based organic polyisocyanate prepolymer (28.5% NCOcontent) that is the reaction product of a fatty acid ester and MDI,prepared according to the general description in U.S. Pat. No. 4,201,847at col. 8, line 30 to col. 10, line 11, the cited portion of which beingincorporated herein by reference.

ISO B: An aromatic isocyanate prepolymer, 23.1% NCO, containing 50-60%by weight 4,4′-diphenylmethane diisocyanate, 20-30% by weight MDIhomopolymer, 15-25% by weight polyurethane prepolymer, and 1-5% byweight MDI mixed isomers

ISO C: Mondur® MR5 (a polymeric MDI (pMDI) containing a relatively highlevel of MDI, NCO content of 32.1%).

The plaques produced in the Examples which follow were produced by thefollowing procedure: A total of 120 grams of the isocyanate/polyolmixture were combined in a suitable container with mixing, in which theamounts of the components were determined based upon the weight ratiolisted in Table 1. The 120 grams of material was placed in a Hauschildmixer and mixed for 30 seconds. After mixing, the material was pouredinto a mold that was maintained at 150° F. The mold produced a plaquemeasuring 150 mm wide×150 mm long×3 mm thick. Prior to molding the moldsurface was treated with a light spray of Chem Trend® MR515 siliconerelease agent and then buffed with a dry, clean cloth. The resultantplaque was allowed to cure for 4 minutes prior to demolding.

TABLE 1 Example # 1 2 3 4 5 6 7 POLYOL A 63.63 63.63 60.6 — — — — POLYOLB 11.11 11.11 10.58 — — — — POLYOL C — — 3.81 — — 3.5 2.0 POLYOL D — — —29.8 29.8 28.8 28.8 POLYOL E — — — 29.8 29.8 28.8 28.8 POLYOL F — — —30.75 30.75 29.25 30.75 ETHYLENE — — — 5.0 5.0 5.0 5.0 GLYCOL BYK 4100.10 0.10 0.10 — — — — DABCO T-12 0.03 0.03 0.03 0.05 0.05 0.05 0.05PIGMENT 1 0.51 0.51 0.51 — — — — PIGMENT 2 — — — 0.80 0.80 0.80 0.80 UOPL 2.02 2.02 1.92 3.6 3.6 3.6 3.6 FILLER 1 12.12 12.12 11.54 — — — —FILLER 2 11.48 11.48 10.94 — — — — ISO A — X X — X X X ISO B X — — — — —— ISO C — — — X — — — Mix Ratio (pbw) 75:100 61:100 67:100 62:100 71:10075:100 73.8:100 Isocyanate:Polyol No. of releases¹ 1-2 >20 >201-2 >20 >20 >20 Shore D Hardness² @ de-mold 25 21 24 20 12 17 15 5 min.after de- 75 43 72 35 17 41 35 mold 1 hr. after de-mold 81 72 80 63 4262 53 Final Shore D 82 77 82 66 51 67 63 Hardness (16 hours afterproduction) ¹The number of release means the number of times that theplaque could be removed from the mold before experiencing undueresistance and/or leaving polyurethane residue behind. ²Shore D hardnessis measured according to ASTM D2240-15

As can be seen from the data presented in Table 1, substitution of ISO Ainto the compositions produced plaques that exhibited significantly morereleases from the mold relative to ISO B and ISO C. In fact, theincrease in number of releases was far more than was expected. Initiallyit was expected that the number of releases would increase from 1-2 toapproximately 10-12 by this substitution. What was observed, however,was at least a two-fold greater number of releases than what wasexpected.

As can also been seen from the data presented in Table 1, meresubstitution of isocyanates as described above in thepolyurethane-forming system did not produce a composite with acceptablephysical properties. After numerous attempts to achieve a desired cureprofile through catalyst modifications, which were not successful, itwas discovered that it was critical to modify the isocyanate-reactivemixture by including a sufficient amount of POLYOL C to provide a plaquewith an adequate cure profile for production as is illustrated by theShore D hardness build over time.

Although the invention has been described in detail in the foregoing forthe purpose of illustration, it is to be understood that such detail issolely for that purpose and that variations can be made therein by thoseskilled in the art without departing from the spirit and scope of theinvention except as it may be limited by the claims.

What is claimed is:
 1. A process of making a filter cartridge assemblycomprising an end member and a body comprising a filter medium,comprising affixing the end member to an end of the body, wherein theend member is a polyurethane elastomer that is a reaction product of anon-foaming reaction mixture comprising an isocyanate-reactivecomposition and an organic polyisocyanate prepolymer having an internalmold release agent, wherein the isocyanate-reactive compositioncomprises 1% to 10% by weight, based on the total weight ofisocyanate-reactive ingredients in the isocyanate-reactive composition,of a polyether tetrol that is an alkylene diamine-alkylene oxide adducthaving a number average molecular weight of 150 to 500 gram/mole.
 2. Theprocess of claim 1, wherein the organic polyisocyanate prepolymercomprises a reaction product of a fatty acid ester and an organicpolyisocyanate.
 3. The process of claim 2, wherein the fatty acid esteris a condensate of oleic acid with a dicarboxylic acid and apolyfunctional alcohol that has a number average molecular weight of 900to 2500 gram/mole and a hydroxyl number of 30 to 70 mg KOH/gram.
 4. Theprocess of claim 1, wherein the polyether tetrol has a number averagemolecular weight 340 to 380 gram/mole.
 5. The process of claim 1,wherein the polyether tetrol is present in an amount of 2% to 6% byweight, based on the total weight of isocyanate-reactive ingredients inthe isocyanate-reactive composition.
 6. The process of claim 1, whereinthe isocyanate-reactive composition further comprises a polyether polyolprepared from an initiator which is not an amine that has a hydroxylfunctionality of greater than 2 and a number average molecular weight of150 to
 450. 7. The process of claim 6, wherein the polyether polyolprepared from an initiator which is not an amine has a functionality of3 and a hydroxyl number of 640 to 660 mg KOH/g.
 8. The process of claim6, wherein the polyether polyol prepared from an initiator which is notan amine (A) and the alkylene diamine-alkylene oxide adduct (B) arepresent in the isocyanate-reactive composition in a relative weightratio of (A):(B) of at least 1:1.
 9. The process of claim 8, wherein therelative weight ratio of (A):(B) is 2:1 to 4:1.
 10. The process of claim8, wherein the isocyanate-reactive composition further comprises apolyether polyol having a hydroxyl functionality of greater than 2 and anumber average molecular weight of 600 to 800 gram/mole.
 11. The processof claim 10, wherein the polyether polyol having a hydroxylfunctionality of greater than 2 and a number average molecular weight of600 to 800 gram/mole is present in an amount of 40 to 80 percent byweight, based on the total weight of the isocyanate-reactivecomposition.
 12. The process of claim 1, wherein the isocyanate-reactivecomposition comprises less than 0.1% by weight of carboxylic acid. 13.The process of claim 1, wherein the isocyanate-reactive compositioncomprises less than 0.5% by weight of zinc carboxylate.
 14. The processof claim 1, wherein the isocyanate-reactive composition does not includean internal mold release agent.
 15. A process for producing a moldedpolyurethane elastomer, comprising depositing a non-foaming reactionmixture into a mold, the non-foaming reaction mixture comprising: (a) anorganic polyisocyanate prepolymer having an internal mold release agent;and (b) an isocyanate-reactive composition comprising: (i) 1% to 10% byweight, based on the total weight of isocyanate-reactive ingredients inthe isocyanate-reactive composition, of a polyether tetrol that is analkylene diamine-alkylene oxide adduct having a number average molecularweight of 150 to 500 gram/mole; (ii) a polyether polyol prepared from aninitiator which is not an amine that has a hydroxyl functionalitygreater than 2 and a number average molecular weight of 150 to 500gram/mole; and (iii) 40 to 80 percent by weight, based on the totalweight of the isocyanate-reactive composition, of a polyether polyolhaving a functionality of 3 and a number average molecular weight of 600to 800 gram/mole, wherein the polyether tetrol (i) and the polyetherpolyol prepared from an initiator which is not an amine (ii) are presentin the isocyanate-reactive composition in a relative weight ratio of 2:1to 4:1.
 16. A process of making a filter cartridge assembly comprisingan end member and a body comprising a filter medium, comprising affixingthe end member to an end of the body, wherein the end member is apolyurethane elastomer that is a reaction product of a non-foamingreaction mixture comprising an isocyanate-reactive composition and anorganic polyisocyanate prepolymer having an internal mold release agent,wherein the isocyanate-reactive composition comprises a mixture ofpolyols formulated to provide a polyurethane elastomer having a Shore Dhardness, measured according to ASTM D2240-15, within 10 minutes afterproduction that is at least 60% of the Shore D hardness of thepolyurethane elastomer measured 16 hours after production.
 17. Theprocess of claim 16, wherein the elastomer has a Shore D hardness of atleast 80 measured 16 hours after production and the Shore D hardnesswithin 10 minutes after production that is at least 80% of the Shore Dhardness of the polyurethane elastomer measured 16 hours afterproduction.